RM38T0EC _54 Brake _113942 BRAKE SYSTEM (OTHER) _0604484 BRAKE BOOSTER(for HEV Model) A

BRAKE SYSTEM (OTHER) BRAKE BOOSTER(for HEV Model) REMOVAL

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

2.594,0.75 2.979,0.75 false 2.896,3.375 3.281,3.375 false 5.135,4.281 5.521,4.281 false 5.479,2.688 5.865,2.688 false 6.438,1.094 6.823,1.094 false 6.427,0.698 6.813,0.698 false 6.427,0.229 6.813,0.229 false 6.208,0.104 6.583,0.49 0.375,0.385 18 false 1 6.219,0.563 6.677,0.917 0.458,0.354 18 false 2 4.927,4.156 5.281,4.521 0.354,0.365 18 false 3 5.281,2.552 5.719,2.958 0.438,0.406 18 false 4 3.031,0.625 3.521,1.021 0.49,0.396 18 false 5 2.688,3.26 3.125,3.635 0.438,0.375 18 false 6 6.24,0.969 6.594,1.333 0.354,0.365 18 false 7 1.5,1.302 1.781,1.656 0.281,0.354 10 false x8 1.031,1.26 1.313,1.615 0.281,0.354 10 false x4

Procedure		Part Name Code
1	PRECAUTION	-	(202307,999999,_54,_113942,_0604484,RM100000002BUHY_01_0068,)	-	-
2	DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
3	FRONT WHEEL LH	-	-	-	-
4	WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY	-	-	-	-
5	NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL	55737B	-	-	-
6	OUTER COWL TOP PANEL SUB-ASSEMBLY	55701J	-	-	-
7	BRAKE FLUID	-	-	(202307,999999,_54,_113942,_0604484,RM100000002BUHY_01_0006,)	-

4.656,0.313 4.802,0.167 4.802,0.167 5.021,0.167 false 3.365,1.792 3.167,1.573 3.167,1.573 2.979,1.573 false 1.531,3.854 1.979,3.854 false 1.448,4.844 1.677,4.844 false 5.604,3.188 6.031,3.188 false 4.99,0.594 5.167,0.427 5.167,0.427 5.385,0.427 false 6.281,1.156 6.5,1.156 false 5.708,0.792 5.927,0.792 false 1.333,3.708 1.792,4.146 0.458,0.438 18 false 8 1.24,4.708 1.781,5.26 0.542,0.552 18 false 8 2.781,1.448 3.323,1.854 0.542,0.406 18 false 8 5.375,0.031 6.167,0.615 0.792,0.583 18 false 9 5.781,0.292 6.396,0.844 0.615,0.552 18 false 9 6.833,1.042 7.135,1.458 0.302,0.417 18 false 9 6.354,0.646 6.792,1.135 0.438,0.49 18 false 10 6.333,3.052 6.896,3.573 0.563,0.521 18 false 11 5.271,0.094 5.792,0.542 0.521,0.448 10 false ● 5.677,0.344 6.229,0.781 0.552,0.438 10 false ● 6.25,0.698 6.719,1.188 0.469,0.49 10 false ● 6.729,1.094 7.146,1.479 0.417,0.385 10 false ●

Procedure		Part Name Code
8	ENGINE ROOM MAIN WIRE	82111	(202307,999999,_54,_113942,_0604484,RM100000002BUHY_01_0074,)	-	-
9	NO. 1 BRAKE TUBE CLAMP	47371A	(202307,999999,_54,_113942,_0604484,RM100000002BUHY_01_0097,)	-	-
10	NO. 2 BRAKE TUBE CLAMP	47372	(202307,999999,_54,_113942,_0604484,RM100000002BUHY_01_0098,)	-	-
11	FRONT NO. 5 BRAKE TUBE	47315	(202307,999999,_54,_113942,_0604484,RM100000002BUHY_01_0094,)	-	-

●

Non-reusable part

1.906,1.802 2.344,2.146 false 1.646,1.833 2.052,2.146 2.052,2.146 2.5,2.146 false 5.771,5.042 6.073,5.292 6.073,5.292 6.302,5.292 false 3.302,2.792 3.906,2.792 false 0.865,4.563 1.167,4.563 1.167,4.563 1.5,4.354 false 5.354,3.563 5.844,3.563 false 4.531,4.844 4.854,4.844 false 5.844,1.354 6.333,1.354 false 2.74,2.031 3.313,2.448 0.573,0.417 18 false 13 6.354,5.177 6.927,5.594 0.573,0.417 18 false 14 3.969,2.667 4.542,3.083 0.573,0.417 18 false 15 0.531,4.396 1.104,4.813 0.573,0.417 18 false 16 6.031,3.438 6.604,3.854 0.573,0.417 18 false 17 4.396,4.75 4.969,5.167 0.573,0.417 10 false ● 5.906,3.458 6.479,3.875 0.573,0.417 10 false ● 6.177,4.115 6.75,4.531 0.573,0.417 10 false x4 5.188,0.302 5.479,0.531 0.292,0.229 10 false x2 6.396,1.208 6.969,1.625 0.573,0.417 18 false 12

Procedure		Part Name Code
12	NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY	55606	-	-	-
13	BRAKE LINE	-	(202307,999999,_54,_113942,_0604484,RM100000002BUHY_01_0075,)	-	-
14	BRAKE PEDAL RETURN SPRING	47101A	-	-	-
15	PUSH ROD PIN	47264A	-	-	-
16	BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY	47210L	(202307,999999,_54,_113942,_0604484,RM100000002BUHY_01_0048,)	-	-
17	BRAKE BOOSTER GASKET	44785	-	-	-

●

Non-reusable part

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during brake booster with master cylinder assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
*1: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation.
Electric brake booster (brake booster with master cylinder assembly)	Update ECU security key (Only necessary after replacement)	Vehicle Control History (RoB) are stored	(202201,202405,_V1,_106911,_0485801,RM100000001XG8S,202405,999999,_V1,_106911,_0485801,RM100000002NHZW,)
	1. Bleed air*1 2. Perform "Reset Memory" 3. Perform "Calibration"	· DTCs are stored · ABS warning light illuminates · Brake system warning light (yellow indicator) illuminates · Slip indicator light illuminates · Electronically controlled brake system disabled or malfunctions	(202307,999999,_54,_113942,_0604471,RM100000002BUFW,) (202307,999999,_54,_112606,_0608077,RM100000002C79U,)

HINT:

When the cable is disconnected/reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven

Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	Link
Front camera system	Drive the vehicle straight ahead at 15 km/h (10 mph) or more for 1 second or more.	(202307,999999,_95,_112293,_0586709,RM100000002BSVY,)

Learning completes when vehicle is operated normally

Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	Link
Power door lock control system · Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.	(202201,999999,_58,_115226,_0510939,RM1000000020BSY,)
Power back door system	Fully close the back door by hand. HINT: Initialization is not necessary if the above procedures are performed while the back door is closed.	(202201,999999,_59,_113746,_0504731,RM100000001ZJKP,)
Air conditioning system	After the ignition switch is turned to ON, the servo motor standard position is recognized.	-

PROCEDURE

Hide Display 1. PRECAUTION

NOTICE:: After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.; Click here(202307,999999,_V1,_106911,_0485800,RM100000002CEKY,)

Hide Display 2.DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

Click hereGeneral>MAINTENANCE>M20F-FXS, M20G-FXS AUXILIARY BATTERY>REMOVAL202307,999999,_V1,_104397,_0604345,RM100000002BTXA,

Hide Display 3.REMOVE FRONT WHEEL LH

Click hereGeneral>MAINTENANCE>TIRE AND WHEEL>REMOVAL202201,999999,_V1,_104397,_0503374,RM100000001ZE9H,

Hide Display 4.REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click hereVehicle Exterior>WIPER / WASHER>FRONT WIPER MOTOR>REMOVAL202201,999999,_59,_114146,_0505960,RM100000001ZPJ0,

Hide Display 55737B 5.REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Click hereSuspension>FRONT SUSPENSION>FRONT SHOCK ABSORBER>REMOVAL202307,999999,_53,_112966,_0502991,RM100000002BYRV_01_0045,

Hide Display 55701J 6.REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SHOCK ABSORBER>REMOVAL202307,999999,_53,_112966,_0502991,RM100000002BYRV_01_0036,

Hide Display 7.DRAIN BRAKE FLUID

NOTICE:: If brake fluid leaks onto any painted surface, immediately wash it off.

Hide Display 82111 8.SEPARATE ENGINE ROOM MAIN WIRE

0.365,0.052 0.875,0.365 0.51,0.313 18 false i, ii 3.938,0.219 4.198,0.51 0.26,0.292 18 true iii 0.99,0.25 1.198,0.458 0.208,0.208 10 true A 0.896,1.25 1.104,1.458 0.208,0.208 10 true B

Push in this direction

Disconnect the connector in this direction

Disconnect the connector (A) from the brake booster assembly.

ii.

Disengage the clamp from the brake master cylinder reservoir assembly.

iii.

Disconnect the connector (B) from the brake master cylinder reservoir assembly as shown in the illustration.

0.365,0.052 0.646,0.406 0.281,0.354 18 false i

	Pressing the lock		Lift the lock lever
	Disconnect the connector	-	-

As shown in the illustration, lift the lock lever while pressing the lock and disconnect the connector from the brake booster assembly.

NOTICE:: Be careful not to allow any brake fluid to enter the connector.

Hide Display 47371A 9.REMOVE NO. 1 BRAKE TUBE CLAMP

NOTICE:: Do not kink or damage the brake lines.

Hide Display 47372 10.REMOVE NO. 2 BRAKE TUBE CLAMP

NOTICE:: Do not kink or damage the brake lines.

Hide Display 47315 11.DISCONNECT FRONT NO. 5 BRAKE TUBE

NOTICE:: ·

Do not kink or damage the brake lines.

·

Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

0.375,0.052 0.646,0.385 0.271,0.333 18 false i 3.906,0.063 4.188,0.375 0.281,0.313 18 false ii 1.958,2.083 2.25,2.417 0.292,0.333 18 false iii

Disconnect in this Direction

Using a union nut wrench, disconnect the front No. 5 brake tube from the front flexible hose LH.

ii.

Disconnect the front brake tube grommet from the vehicle body as shown in the illustration.

iii.

Using a union nut wrench, disconnect the front No. 5 brake tube from the brake actuator assembly.

Hide Display 55606 12.REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click hereVehicle Interior>INTERIOR PANELS / TRIM>FRONT CONSOLE BOX>REMOVAL202307,999999,_58,_112291,_0501086,RM100000002BHCH_01_0060,

Hide Display 13.DISCONNECT BRAKE LINE

Click here(

202307,999999,_54,_113942,_0604483,RM100000002BUHU_01_0070,)

Hide Display 47101A 14.REMOVE BRAKE PEDAL RETURN SPRING

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE PEDAL (for HEV Model)>REMOVAL202307,999999,_54,_113942,_0604479,RM100000002BUGW_01_0004,

Hide Display 47264A 15.REMOVE PUSH ROD PIN

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE PEDAL (for HEV Model)>REMOVAL202307,999999,_54,_113942,_0604479,RM100000002BUGW_01_0005,

Hide Display 47210L 16.REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

0.573,0.115 0.854,0.469 0.281,0.354 18 false i

Remove the 4 nuts and brake booster with master cylinder assembly.

NOTICE:

Do not kink or damage the brake lines.

0.354,0.708 0.552,0.708 false 2.677,0.792 2.677,0.542 2.677,0.542 2.844,0.542 false 1.104,1.552 1.125,1.813 1.125,1.813 1.958,0.604 true 2.521,1.031 2.521,1.448 false 1.042,1.833 1.354,2.031 0.313,0.198 10 false *a 2.448,1.469 2.76,1.667 0.313,0.198 10 false *b 2.885,0.479 3.198,0.677 0.313,0.198 10 false *c 0.177,0.635 0.49,0.833 0.313,0.198 10 false *d

*a	Connectors
*b	Boot
*c	Brake Master Cylinder Push Rod Clevis
*d	Brake Master Cylinder Reservoir Assembly

Do not carry the brake booster with master cylinder assembly by the parts shown in the illustration.

Be careful not to allow any brake fluid to enter the connector.

Hide Display 44785 17.REMOVE BRAKE BOOSTER GASKET